Page 1 2014 SERVICE MANUAL XVS950CU XVS950CUE 1XC-28197-E0...
Page 2 EAS20040 XVS950CU/XVS950CUE 2014 SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, November 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE ABS (for ABS models) ..........1-4 ABS COMPONENT FUNCTIONS ............. 1-9 ABS OPERATION ...................1-15 ABS WARNING LIGHT AND OPERATION..........1-18 INSTRUMENT FUNCTIONS ..............
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS5S71022 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS5S71020 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 220–300 kPa (2.20–3.00 kg/cm², 31.3–42.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Outline Of The Abs (For Abs Models)
EAS1XC1022 OUTLINE OF THE ABS (for ABS models) 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
Page 14 FEATURES The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. When wheel lock is detected during emergency braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
Page 15 FEATURES a. Friction force between the tire and road e. Less slippery road surface surface f. Controlling zone b. Brake force g. Slippery road surface c. Side force d. Slip ratio (%) Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors.
Page 16 FEATURES a. Chassis speed d. Depressurizing phase b. Wheel speed e. Pressurizing phase c. Brake force ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control.
Page 17 Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
Page 18: Abs Component Functions
FEATURES ABS block diagram 1. Front brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Front brake caliper 3. Rear brake master cylinder 11. Front wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
Page 19 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on during the ABS self-diagnosis to check the electrical circuit of the light.
Page 20 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
Page 21 FEATURES • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston 1-12...
Page 22 FEATURES • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 1.
Page 23 FEATURES • Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS ECU fuse). • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on.
Page 24: Abs Operation
FEATURES EAS1XC1024 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 25 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 26 FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 27: Abs Warning Light And Operation
FEATURES EAS1XC1025 ABS WARNING LIGHT AND OPERATION ABS function EWA1XC1005 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal.
Page 28: Instrument Functions
FEATURES EAS5S71021 2. “RESET” switch INSTRUMENT FUNCTIONS Odometer, tripmeters, fuel reserve tripmeter Multi-function meter unit and clock 1. Speedometer 1. Odometer/tripmeter/fuel reserve tripmeter 2. Odometer/tripmeter/fuel reserve tripmeter/clock Push the “SELECT” switch to switch the display between the odometer mode “ODO”, the tripme- EWA12422 WARNING ter modes “TRIP 1”...
Page 29 FEATURES To set the clock If the display indicates fault code 52, this could be caused by transponder interference. If this fault code appears, try the following. 1. Use the code re-registering key to start the engine. Make sure there are no other immobilizer keys close to the main switch, and do not keep more than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter-...
Page 30: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 31: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 EAS1TP1072 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings and oil seals so that the manu- Check rubber parts for deterioration during in- facturer’s marks or numbers are visible. When spection. Some of the rubber parts are sensitive installing oil seals “1”, lubricate the oil seal lips to gasoline, flammable oil, grease, etc.
Page 32: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 33: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 34 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
Page 35 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 36 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
Page 37: Special Tools
7-167, 7-167, 7-168, 7-168, 7-169, 7-169 Thickness gauge 3-6, 3-6, 3-6, 90890-03180 4-18, 4-29 Feeler gauge set YU-26900-9 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Digital tachometer 3-8, 7-165 90890-06760 YU-39951-B Yamaha diagnostic tool 3-9, 4-67, 4-69, 90890-03215 7-45, 7-119, 7-145 1-28...
Page 38 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Belt tension gauge 3-18 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-19, 4-87 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-24 90890-01426 YU-38411 Damper rod holder (22 mm) 4-80, 4-82 90890-01365 T-handle...
Page 39 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 90890-04136 Boots band installation tool 90890-01526 YM-01526 Rotor holding tool 5-19, 5-23, 90890-01235 5-24 Universal magneto & rotor holder YU-01235 Slide hammer bolt 5-20 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-20 90890-01084...
Page 40 Piston pin puller set 5-37 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder 5-45, 5-45, 90890-01701 5-46, 5-46, Primary clutch holder 5-53, 5-58 YS-01880-A Flywheel puller 5-45 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-46, 5-70 90890-85505 (Three Bond No.1215®) 1-31...
Page 41 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-53, 5-56 90890-04086 YM-91042 Digital circuit tester 5-63, 6-10, 90890-03174 7-164 Model 88 Multimeter with tachometer YU-A1927 Vacuum/pressure pump gauge set 6-10 90890-06756 Mityvac brake bleeding tool YS-42423 Pressure gauge 6-10 90890-03153 YU-03153...
Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness S– pressure sensor (3P) 7-167 90890-03207 YU-03207 Test harness S– pressure sensor 5S7 7-168 (3P) 90890-03211 YU-03211 1-33...
Page 43: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-27 ENGINE....................2-27 CHASSIS....................2-29 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 44: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS950CU 1XC1 (Europe)(for ABS models) XVS950CU 2DX7 (Europe)(for ABS models) XVS950CU 2DE1 (Europe)(except for ABS models) XVS950CU 2DA1 (AUS)(except for ABS models) XVS950CUE 2DX5 (AUS)(except for ABS models) Dimensions Overall length 2290 mm (90.2 in) Overall width 830 mm (32.7 in) Overall height...
Page 45: Engine Specifications
ENGINE SPECIFICATIONS EAS20291 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 942 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 85.0 × 83.0 mm (3.35 × 3.27 in) Compression ratio 9.00 : 1 Standard compression pressure (at sea level) 1400 kPa/400 r/min (14.0 kgf/cm²/400 r/min, 199.1 psi/400 r/min) Minimum-maximum...
Page 46 ENGINE SPECIFICATIONS Warpage limit 0.03 mm (0.0012 in) Camshaft Drive system Chain drive (left and right) Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720–1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583–1.4622 in) Limit 36.941 mm (1.4544 in) Exhaust A 42.138–42.238 mm (1.6590–1.6629 in) Limit...
Page 47 ENGINE SPECIFICATIONS Valve face width B (exhaust) 2.300 mm (0.0906 in) Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake) 1.00 mm (0.0394 in) Valve margin thickness D (exhaust) 1.00 mm (0.0394 in)
Page 48 ENGINE SPECIFICATIONS Installed compression spring force (exhaust) 171.00–197.00 N (17.44–20.09 kgf, 38.44– 44.29 lbf) Spring tilt (intake) 2.5 °/1.9 mm (0.07 in) Spring tilt (exhaust) 2.5 °/1.9 mm (0.07 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 85.000–85.010 mm (3.3465–3.3468 in) Wear limit 85.100 mm (3.3504 in)
Page 49 ENGINE SPECIFICATIONS Dimensions (B × T) 1.20 × 3.30 mm (0.05 × 0.13 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×...
Page 50 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 5-speed Primary reduction ratio 1.674 (72/43) Final drive Belt Secondary reduction ratio 2.333 (70/30) Operation Left foot operation Gear ratio 3.067 (46/15) 2.063 (33/16) 1.579 (30/19) 1.259 (34/27) 1.042 (25/24) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
Page 51 ENGINE SPECIFICATIONS Oil temperature 60.0–70.0 °C (140.00–158.00 °F) Throttle grip free play 4.0–6.0 mm (0.16–0.24 in)
Page 52: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 29.00 ° Trail 130 mm (5.1 in) Front wheel Wheel type Cast wheel 19M/C × MT2.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 53 Spring stroke K1 0.0–120.0 mm (0.00–4.72 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 547.0 cm³ (18.49 US oz, 19.29 Imp.oz) Level 116.0 mm (4.57 in) Rear suspension Type...
Page 54 CHASSIS SPECIFICATIONS Spring/shock absorber type Coil spring/oil damper (for models not equipped with gas cylinders) Coil spring/gas-oil damper (for models equipped with gas cylinders) Rear shock absorber assembly travel 51.0 mm (2.01 in) Spring free length 167.7 mm (6.60 in) (for models not equipped with gas cylinders) 128.5 mm (5.06 in) (for models equipped with gas cylinders)
Page 55: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 5.0 °/1000 r/min Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
Page 56 ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light LED (for ABS models) Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.0050–0.0150 Ω Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force...
Page 57 ELECTRICAL SPECIFICATIONS Spare fuse 15.0 A Spare fuse 10.0 A Spare fuse 7.5 A Spare fuse 30.0 A (for ABS models) 2-14...
Page 58: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 59: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Oil check bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Cylinder head nut 65 Nm (6.5 m·kgf, 47 ft·lbf) See TIP Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Page 60 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump housing screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) Oil filter cartridge union bolt 70 Nm (7.0 m·kgf, 51 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf)
Page 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size l = 40 mm (1.57 in) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) See TIP l = 40 mm (1.57 in) Clutch cover bolt (with washer) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) See TIP l = 65 mm (2.56 in)
Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Speed sensor bracket bolt (ex- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) cept for ABS models) Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Inlet pipe assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Pressure regulator 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Cylinder head nut...
Page 63 TIGHTENING TORQUES Generator cover bolt Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illus- tration. Clutch cover bolt Temporally tighten the bolts “a” and “b”, and then tighten the clutch cover bolts in the order shown in the illustration.
Page 64: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (front upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (front lower 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear lower...
Page 65 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) See TIP Front brake caliper bracket bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) Front brake caliper retaining bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) Front brake disc bolt...
Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake hose holder and low- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) er bracket bolt Front brake hose holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Front fender bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Headlight bracket bolt 19 Nm (1.9 m·kgf, 14 ft·lbf) Headlight lens unit screw...
Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel sender screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank and fuel tank bracket 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bolt Fuel tank bracket and frame bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Rider seat bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) Rider seat holder bolt...
Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel sensor bolt (for ABS 7 Nm (0.7 m·kgf, 5.1 ft·lbf) models) Rear wheel sensor bolt (for ABS 7 Nm (0.7 m·kgf, 5.1 ft·lbf) models) Rear wheel sensor lead holder 7 Nm (0.7 m·kgf, 5.1 ft·lbf) bolt (for ABS models) Hydraulic unit assembly union...
Page 69 TIGHTENING TORQUES Lower ring nut 1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kgf, 37 ft·lbf) with a torque wrench, then loosen the lower ring nut completely. 2. Retighten the lower ring nut to 18 Nm (1.8 m·kgf, 13 ft·lbf) with a torque wrench. 2-26...
Page 70: Lubrication Points And Lubricant Types
Oil pump drive sprocket (inner surface) Clutch thrust washers Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift Yamaha bond No.1215 Crankcase (mating surface) (Three Bond No.1215®) 2-27...
Page 71 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®) Yamaha bond No.1215 Crankcase breather pipe (Three Bond No.1215®) 2-28...
Page 72: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing race cover (lip) Lower bearing steering seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point) Sidestand (pivoting point) and metal-to-metal moving parts Footrest assembly (pivoting point)
Page 73 LUBRICATION POINTS AND LUBRICANT TYPES 2-30...
Page 74: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Oil delivery pipe 2 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankshaft 10. Clutch cover 11. Valve stem end (intake side) 12.
Page 76: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 2 3. Relief valve assembly 2-34...
Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 2-36...
Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil drain bolt 2. Crankshaft 2-38...
Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 1 3. Main axle 4. Oil delivery pipe 2 5. Oil pump assembly 6. Oil strainer 2-40...
Page 84: Cable Routing (Except For Abs Models)
CABLE ROUTING (except for ABS models) EAS1XC1003 CABLE ROUTING (except for ABS models) Handlebar (top and front view) 2-41...
Page 85 CABLE ROUTING (except for ABS models) 1. Clutch cable 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Front brake hose 5. Right handlebar switch lead 6. Left handlebar switch lead 7. Intake air temperature sensor 8. Intake air temperature sensor sub-wire harness 9.
Page 86 CABLE ROUTING (except for ABS models) Headlight 2-43...
Page 87 CABLE ROUTING (except for ABS models) 1. Intake air temperature sensor sub-wire harness 2. Headlight lead 3. Headlight coupler 4. Auxiliary light lead 5. Auxiliary light coupler 6. Intake air temperature sensor coupler 7. Front brake hose 8. Throttle cables 9.
Page 88 CABLE ROUTING (except for ABS models) Steering head cable (right side view) 2-45...
Page 89 CABLE ROUTING (except for ABS models) 1. Clutch cable V. Route the front left turn signal light lead over the guide on the meter bracket. 2. Joint coupler W. Route the right handlebar switch lead through the 3. Throttle cable (accelerator cable) guide on the meter bracket.
Page 90 CABLE ROUTING (except for ABS models) Clutch cable (right side view) 2-47...
Page 91 CABLE ROUTING (except for ABS models) 1. Lean angle sensor 2. Tail sub-wire harness 3. Wire harness 4. Clutch cable 5. Starter motor lead 6. Rear brake light switch 7. O sensor 8. Brake fluid reservoir hose 9. Positive battery lead 10.
Page 92 CABLE ROUTING (except for ABS models) Frame (inner side view) 2-49...
Page 93 CABLE ROUTING (except for ABS models) 1. Clutch cable 2. Wire harness 3. Crankshaft position sensor lead 4. Oil level switch lead 5. Neutral switch lead 6. Starter motor lead 7. Rear brake hose 8. O sensor 9. Rear brake light switch lead 10.
Page 94 CABLE ROUTING (except for ABS models) Rear brake hose (right side view) 2-51...
Page 95 CABLE ROUTING (except for ABS models) 1. Brake fluid reservoir hose 2. Rear brake light switch 3. Rear brake hose A. Install the brake fluid reservoir hose with its white paint mark facing inward. B. Do not install the hose clamp on the flange at the end of the hose fitting.
Page 96 CABLE ROUTING (except for ABS models) Front brake hose (front and left side view) 2-53...
Page 97 CABLE ROUTING (except for ABS models) 1. Front brake hose 2. Cable guide 3. Brake hose holder A. Route the front brake hose through the cable guide. – ° B. 20 C. Fasten the front brake hose with the holder, making sure that the paint mark on the hose is visible through the hole in the holder.
Page 98 CABLE ROUTING (except for ABS models) Steering head (left side view) 2-55...
Page 99 CABLE ROUTING (except for ABS models) 1. Right handlebar switch lead 2. Left handlebar switch lead 3. Main switch lead 4. Fuel pump lead 5. Main switch couplers 6. Rear cylinder injector lead 7. Front cylinder injector coupler 8. ISC (idle speed control) unit coupler 9.
Page 100 CABLE ROUTING (except for ABS models) Spark plug lead 2-57...
Page 101 CABLE ROUTING (except for ABS models) 1. Front cylinder spark plug lead 2. Fuel return hose 3. Fuel tank breather hose 4. Fuel tank bracket 5. Frame 6. Clutch cable 7. Rear right cylinder head cover 8. Wire harness 9. Hose holder 10.
Page 102 CABLE ROUTING (except for ABS models) Electrical components tray (left side view) 2-59...
Page 103 13. Turn signal/hazard relay 14. Relay unit 15. Lean angle sensor lead 16. Starter motor lead 17. Main fuse Yamaha diagnostic tool coupler 19. Speed sensor lead 20. Ground lead A. After connecting the couplers, cover the couplers with the coupler cover, and then place the couplers in the air duct.
Page 104 CABLE ROUTING (except for ABS models) Rectifier/regulator (rear view) 2-61...
Page 105 CABLE ROUTING (except for ABS models) 1. Starter motor lead 2. Clutch cable 3. Brake fluid reservoir hose 4. O sensor lead 5. Rear brake hose 6. Rear brake light switch lead 7. Lean angle sensor 8. Rear turn signal light and license plate light sub- wire harness coupler 9.
Page 106 CABLE ROUTING (except for ABS models) Rear fender (top and left view) 2-63...
Page 107 CABLE ROUTING (except for ABS models) 1. Tail sub-wire harness 2. Tail/brake light 3. License plate light 4. Rear left turn signal light lead 5. Rear left turn signal light 6. Tail/brake light lead 7. Rear left turn signal light coupler 8.
Page 108 CABLE ROUTING (except for ABS models) Fuel tank 2-65...
Page 109 CABLE ROUTING (except for ABS models) 1. Fuel tank breather/overflow hose (fuel tank to hose joint) 2. Fuel tank breather/overflow hose (hose joint to rollover valve) 3. Hose joint 4. Fuel filter 5. Fuel hose (fuel pump to fuel filter) 6.
Page 110 CABLE ROUTING (except for ABS models) Fuel tank breather hose (left and rear view) 2-67...
Page 111 CABLE ROUTING (except for ABS models) 1. Fuel tank breather/overflow hose (hose joint to rollover valve) 2. Rollover valve 3. Fuel tank breather/overflow hose (from rollover valve) A. Route the fuel tank breather hose (hose joint to rollover valve) to the left of the battery box. –...
Page 112 CABLE ROUTING (except for ABS models) Fuel tank breather hose (right side view) 2-69...
Page 113 CABLE ROUTING (except for ABS models) 1. Intake air pressure hose 2. Intake air pressure sensor 3. Fuel tank breather hose (hose joint to rollover valve) A. Point the ends of the hose clamp to the right. B. Install the intake air pressure hose with its white paint mark facing to the right.
Page 114 CABLE ROUTING (except for ABS models) Intake air pressure sensor hose (top view) 2-71...
Page 115 CABLE ROUTING (except for ABS models) 1. Intake air pressure sensor hose 2. Hose fitting A. Point the ends of the hose clamp to the right. B. Install the intake air pressure sensor hose completely onto the hose fitting, making sure that the yellow paint mark on the hose is facing upward.
Page 116 CABLE ROUTING (except for ABS models) Crankcase breather hose (left side view) 2-73...
Page 117 CABLE ROUTING (except for ABS models) 1. Crankcase breather hose 2. Crankcase 3. Air filter case A. Install the crankcase breather hose with its white paint mark facing upward. B. Point the ends of the hose clamp rearward, angled upward. C.
Page 118: Cable Routing (For Abs Models)
CABLE ROUTING (for ABS models) EAS1XC1004 CABLE ROUTING (for ABS models) Handlebar (top and front view) 2-75...
Page 119 CABLE ROUTING (for ABS models) 1. Clutch cable 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Brake pipe/hose assembly (front brake master cylinder to hydraulic unit) 5. Right handlebar switch lead 6. Left handlebar switch lead 7. Intake air temperature sensor 8.
Page 120 CABLE ROUTING (for ABS models) Headlight 2-77...
Page 121 CABLE ROUTING (for ABS models) 1. Intake air temperature sensor sub-wire harness 2. Headlight lead 3. Headlight coupler 4. Auxiliary light lead 5. Auxiliary light coupler 6. Intake air temperature sensor coupler 7. Brake pipe/hose assembly (front brake master cylinder to hydraulic unit) 8.
Page 122 CABLE ROUTING (for ABS models) Steering head cable (right side view) 2-79...
Page 123 CABLE ROUTING (for ABS models) 1. Clutch cable V. Route the left handlebar switch lead through the guide on the meter bracket. Make sure that there is 2. Joint coupler no slack in the handlebar switch lead between the 3. Throttle cable (accelerator cable) steering head and the plastic band installed on the 4.
Page 124 CABLE ROUTING (for ABS models) Clutch cable (right side view) 2-81...
Page 125 CABLE ROUTING (for ABS models) 1. Lean angle sensor 2. Tail sub-wire harness 3. Wire harness 4. Clutch cable 5. Starter motor lead 6. Rear brake light switch 7. O sensor 8. Rear wheel sensor coupler 9. Rear wheel sensor lead 10.
Page 126 CABLE ROUTING (for ABS models) Frame (inner side view) 2-83...
Page 127 CABLE ROUTING (for ABS models) 1. Clutch cable 2. Wire harness 3. ABS ECU lead 4. Crankshaft position sensor lead 5. Oil level switch lead 6. Neutral switch lead 7. Starter motor lead 8. Brake hose (rear brake master cylinder to hydraulic unit) 9.
Page 128 CABLE ROUTING (for ABS models) Rear brake hose (right side view) 2-85...
Page 129 CABLE ROUTING (for ABS models) 1. Brake hose (rear brake master cylinder to hydraulic unit) 2. Rear brake fluid reservoir hose 3. Rear brake light switch 4. Brake hose (hydraulic unit to rear brake caliper) 5. Rear wheel sensor lead A.
Page 130 CABLE ROUTING (for ABS models) Hydraulic unit (inner and left side view) 2-87...
Page 131 CABLE ROUTING (for ABS models) 1. Wire harness 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Brake hose (hydraulic unit to front brake caliper) 4. Brake hose (rear brake master cylinder to hydraulic unit) 5. Brake hose (hydraulic unit to rear brake caliper) 6.
Page 132 CABLE ROUTING (for ABS models) Front brake hose (front and right side view) 2-89...
Page 133 CABLE ROUTING (for ABS models) 1. Brake pipe/hose assembly (front brake master cylinder to hydraulic unit) 2. Front wheel sensor lead A. Route the brake pipe/hose assembly (front brake master cylinder to hydraulic unit) through the cable guide. B. Route the brake pipe/hose assembly (front brake master cylinder to hydraulic unit) between the front fork and the pipe section of the lower bracket.
Page 134 CABLE ROUTING (for ABS models) Front brake hose (left side view) 2-91...
Page 135 CABLE ROUTING (for ABS models) 1. Brake pipe/hose assembly (front brake master cylinder to hydraulic unit) 2. Front wheel sensor lead 3. Brake hose (hydraulic unit to front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) 5.
Page 136 CABLE ROUTING (for ABS models) Steering head (left side view) 2-93...
Page 137 CABLE ROUTING (for ABS models) 1. Right handlebar switch lead 2. Left handlebar switch lead 3. Front wheel sensor lead 4. Front wheel sensor coupler holder 5. Main switch lead 6. Fuel pump lead 7. Main switch coupler 8. Rear cylinder injector lead 9.
Page 138 CABLE ROUTING (for ABS models) Spark plug lead 2-95...
Page 139 CABLE ROUTING (for ABS models) 1. Front cylinder spark plug lead 2. Fuel return hose 3. Brake hose (hydraulic unit to front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) 5. Fuel tank breather hose 6. Frame 7.
Page 140 CABLE ROUTING (for ABS models) Electrical components tray (left side view) 2-97...
Page 141 15. Turn signal/hazard relay 16. Relay unit 17. Lean angle sensor lead 18. Starter motor lead 19. Main fuse Yamaha diagnostic tool coupler 21. Ground lead A. After connecting the couplers, cover the couplers with the coupler cover, and then place the couplers in the air duct.
Page 142 CABLE ROUTING (for ABS models) Rectifier/regulator (rear view) 2-99...
Page 143 CABLE ROUTING (for ABS models) 1. Starter motor lead 2. Clutch cable 3. Brake fluid reservoir hose 4. O sensor lead 5. Rear brake hose 6. Rear brake light switch lead 7. Rear wheel sensor lead 8. Lean angle sensor 9.
Page 144 CABLE ROUTING (for ABS models) Rear fender (top and left view) 2-101...
Page 145 CABLE ROUTING (for ABS models) 1. Tail sub-wire harness 2. Tail/brake light 3. License plate light 4. Rear left turn signal light lead 5. Rear left turn signal light 6. Tail/brake light lead 7. Rear left turn signal light coupler 8.
Page 146 CABLE ROUTING (for ABS models) Fuel tank 2-103...
Page 147 CABLE ROUTING (for ABS models) 1. Fuel tank breather/overflow hose (fuel tank to hose joint) 2. Fuel tank breather/overflow hose (hose joint to rollover valve) 3. Hose joint 4. Fuel filter 5. Fuel hose (fuel pump to fuel filter) 6. Fuel pump 7.
Page 148 CABLE ROUTING (for ABS models) Fuel tank breather hose (left and rear view) 2-105...
Page 149 CABLE ROUTING (for ABS models) 1. Fuel tank breather/overflow hose (hose joint to rollover valve) 2. Rollover valve 3. Fuel tank breather/overflow hose (from rollover valve) A. Route the fuel tank breather hose (hose joint to rollover valve) to the left of the battery box. –...
Page 150 CABLE ROUTING (for ABS models) Fuel tank breather hose (right side view) 2-107...
Page 151 CABLE ROUTING (for ABS models) 1. Intake air pressure hose 2. Intake air pressure sensor 3. Fuel tank breather hose (hose joint to rollover valve) A. Point the ends of the hose clamp to the right. B. Install the intake air pressure hose with its white paint mark facing to the right.
Page 152 CABLE ROUTING (for ABS models) Intake air pressure sensor hose (top view) 2-109...
Page 153 CABLE ROUTING (for ABS models) 1. Intake air pressure sensor hose 2. Hose fitting A. Point the ends of the hose clamp to the right. B. Install the intake air pressure sensor hose completely onto the hose fitting, making sure that the yellow paint mark on the hose is facing upward.
Page 154 CABLE ROUTING (for ABS models) Crankcase breather hose (left side view) 2-111...
Page 155 CABLE ROUTING (for ABS models) 1. Crankcase breather hose 2. Crankcase 3. Air filter case A. Install the crankcase breather hose with its white paint mark facing upward. B. Point the ends of the hose clamp rearward, angled upward. C. Route the crankcase breather hose over the timing chain tensioner.
Page 156 CABLE ROUTING (for ABS models) 2-113...
Page 157: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 CHECKING THE CRANKCASE BREATHER HOSE ........3-7 SYNCHRONIZING THE THROTTLE BODIES..........
Page 158 CHECKING AND LUBRICATING THE CABLES ........3-26 CHECKING THE THROTTLE GRIP OPERATION .........3-26 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE ...3-27 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-27 ADJUSTING THE HEADLIGHT BEAM ...........3-27 REPLACING THE HEADLIGHT BULB............3-28 REPLACING THE AUXILIARY LIGHT BULB..........3-28...
Page 160: Periodic Maintenance
UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
Page 161 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check for cracks or damage. √ √ √ √ √...
Page 162 PERIODIC MAINTENANCE EAU18681 • Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Page 163: Checking The Fuel Line
PERIODIC MAINTENANCE 5. Check: EAS21030 CHECKING THE FUEL LINE • Electrode The following procedure applies to all of the fuel Damage/wear → Replace the spark plug. and breather hoses. • Insulator 1. Remove: Abnormal color → Replace the spark plug. •...
Page 164 PERIODIC MAINTENANCE 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 6-1. • Front cylinder left cover • Front cylinder right cover • Rear cylinder left cover • Rear cylinder right cover Refer to “ENGINE REMOVAL” on page 5-3. 2.
Page 165 PERIODIC MAINTENANCE c. Measure the valve clearance with a thickness gauge. • When the piston is at TDC on the compression stroke, there should be clearance between the Thickness gauge valve stem tips and their respective rocker arm 90890-03180 adjusting screws. Feeler gauge set •...
Page 166: Checking The Crankcase Breather Hose
PERIODIC MAINTENANCE ECA13450 NOTICE Locknut (rocker arm adjusting screw) Make sure the crankcase breather hose is 27 Nm (2.7 m·kgf, 20 ft·lbf) routed correctly. e. Measure the valve clearance again. f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained.
Page 167 PERIODIC MAINTENANCE 4. Disconnect: c. If the vacuum pressure of the throttle body • Intake air pressure sensor hose “1” with the lower pressure is out of specification, • Cap “2” adjust it to specification first, and then syn- chronize the throttle bodies. 5.
Page 168: Checking The Exhaust System
• Muffler “3” tion manual of the Yamaha diagnostic tool. • Gaskets “4”, “5” Exhaust gas leaks → Replace. 1. Connect the Yamaha diagnostic tool to the 2. Check: coupler. For information about connecting the Tightening torque Yamaha diagnostic tool, refer to “YAMAHA •...
Page 169: Checking The Clutch Operation
PERIODIC MAINTENANCE EAS1TP1017 CHECKING THE CLUTCH OPERATION 1. Check: • Clutch operation Dysfunctional → Check the clutch system. Refer to “CLUTCH” on page 5-48. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 170: Checking The Brake Operation
PERIODIC MAINTENANCE Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating fully. EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. c.
Page 171: Checking The Front Brake Pads
PERIODIC MAINTENANCE • When refilling, be careful that water does not enter the brake master cylinder reser- voir and brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.
Page 172: Bleeding The Hydraulic Brake System (For Abs Models)
PERIODIC MAINTENANCE 2. Bleed: k. Fill the brake master cylinder reservoir or • Hydraulic brake system brake fluid reservoir to the proper level with the specified brake fluid. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 173: Checking The Front Brake Hose
PERIODIC MAINTENANCE 1. Remove: • Brake fluid reservoir cover “1” Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the After removing the brake fluid reservoir cover, in- throttle grip or the brake pedal to fully extend. stall the brake fluid reservoir temporarily.
Page 174: Checking The Rear Brake Hoses
PERIODIC MAINTENANCE A. Except for ABS models A. Except for ABS models B. For ABS models B. For ABS models 2. Check: 2. Check: • Brake hose holder • Brake hose holders Loose → Tighten the holder bolt. Loose → Tighten the holder bolt. 3.
Page 175 PERIODIC MAINTENANCE 1. Check: EWA13190 WARNING • Tire pressure Out of specification → Regulate. It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • Tire surfaces Damage/wear →...
Page 176: Checking The Wheel Bearings
• Swingarm pivot shaft bearings en if a tire combination other than one Refer to “SWINGARM AND REAR SHOCK approved by Yamaha is used on this vehicle. ABSORBER ASSEMBLIES” on page 4-89. Front tire EAS1TP1022...
Page 177: Adjusting The Drive Belt Slack
PERIODIC MAINTENANCE 2. Rotate the rear wheel several times and check the drive belt to locate its tightest point. 3. Check: • Drive belt slack “a” Out of specification → Adjust. Drive belt slack (on a suitable stand) 7.0–9.0 mm (0.28–0.35 in) Belt tension gauge 90890-03170 3.
Page 178: Checking And Adjusting The Steering Head
PERIODIC MAINTENANCE EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the b.
Page 179: Lubricating The Steering Bearings
PERIODIC MAINTENANCE Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kgf, 38 ft·lbf) Set the torque wrench at a right angle to the steering nut wrench. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 180: Checking The Sidestand
PERIODIC MAINTENANCE EAS1TP1028 CHECKING THE SIDESTAND SWITCH Recommended lubricant Refer to “ELECTRICAL COMPONENTS” on Lithium-soap-based grease page 7-147. EAS1TP1027 EAS21530 CHECKING THE SIDESTAND CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING...
Page 181: Adjusting The Rear Shock Absorber Assemblies (For Models Not Equipped With Gas Cylinders)
PERIODIC MAINTENANCE Refer to “SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES” on page 4-89. EAS1XC1031 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES (for models not equipped with gas cylinders) The following procedure applies to both of the rear shock absorber assemblies. EWA1TP1013 WARNING •...
Page 182: Checking The Engine Oil Level
PERIODIC MAINTENANCE Adjusting positions Standard 1 notch out* Minimum (soft) 0 notches out* Maximum (hard) 4 notches out* *: from the fully turned-in posi- tion Recommended brand YAMALUBE Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard MA 10 30 50 70 90 110...
Page 183: Changing The Engine Oil
PERIODIC MAINTENANCE b. Lubricate the O-ring “3” of the new oil filter EAS20780 CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil. 1. Start the engine, warm it up for several min- ECA13390 utes, and then turn it off. NOTICE 2.
Page 184: Checking The Brake Light Switch
PERIODIC MAINTENANCE 10.Start the engine, warm it up for several min- 15.Install: utes, and then turn it off. • Rear cylinder right cover bracket 11.Check: • Rear cylinder right cover • Engine Rear cylinder right cover bracket (for engine oil leaks) bolt 12.Check: 20 Nm (2.0 m·kgf, 14 ft·lbf)
Page 185: Checking And Lubricating The Cables
PERIODIC MAINTENANCE With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right. 3.
Page 186: Lubricating The Throttle Grip Housing And Cable
PERIODIC MAINTENANCE EAS1TP1034 CHECKING THE SWITCHES, LIGHTS AND SIGNALS 1. Check that all switches operate and that all lights come on. Refer to “INSTRUMENT AND CONTROL FUNCTIONS” in Owner’s manual. → Faulty Refer to “CHECKING THE SWITCHES” on page 7-151 and “CHECK- ING THE BULBS AND BULB SOCKETS”...
Page 187: Replacing The Headlight Bulb
PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 ▲...
Page 188 PERIODIC MAINTENANCE 3. Remove: • Auxiliary light bulb “1” 4. Install: • Auxiliary light bulb • Auxiliary light socket 5. Install: • Headlight lens unit Refer to “GENERAL CHASSIS” on page 4-1. 3-29...
Page 189: Chassis
CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE TOOL BOX ..............4-5 FRONT WHEEL..................... 4-10 REMOVING THE FRONT WHEEL............4-13 DISASSEMBLING THE FRONT WHEEL..........4-13 CHECKING THE FRONT WHEEL ............4-13 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR (for ABS models) ............4-14 ASSEMBLING THE FRONT WHEEL............4-15 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......
Page 190 REAR BRAKE ....................4-45 INTRODUCTION ..................4-53 CHECKING THE REAR BRAKE DISC............4-53 REPLACING THE REAR BRAKE PADS..........4-53 REMOVING THE REAR BRAKE CALIPER ..........4-54 DISASSEMBLING THE REAR BRAKE CALIPER ........4-54 CHECKING THE REAR BRAKE CALIPER..........4-55 ASSEMBLING THE REAR BRAKE CALIPER ........4-55 INSTALLING THE REAR BRAKE CALIPER...........4-55 REMOVING THE REAR BRAKE MASTER CYLINDER ......
Page 191 BELT DRIVE....................4-92 REMOVING THE DRIVE BELT AND DRIVE PULLEY ......4-93 CHECKING THE DRIVE BELT ...............4-93 INSTALLING THE DRIVE BELT AND DRIVE PULLEY ......4-93...
Page 192: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and side cover 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • • •...
Page 193: Installing The Rider Seat
GENERAL CHASSIS EAS1TP1013 INSTALLING THE RIDER SEAT 1. Install: • Rider seat “1” Rider seat bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) • Insert the projection “a” on the rear of the seat into the seat holder “b” as shown. •...
Page 194 GENERAL CHASSIS Removing the battery and relays 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Side cover 4-1.
Page 195 GENERAL CHASSIS Removing the battery and relays 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter relay coupler Disconnect. Starter relay cover Starter motor lead Disconnect.
Page 196: Installing The Tool Box
GENERAL CHASSIS EAS1TP1065 INSTALLING THE TOOL BOX 1. Install: • Tool box “1” Install the tool box with the “INSIDE” mark “a” facing inward.
Page 197 GENERAL CHASSIS Removing the air filter case 4.2 Nm (0.42 m kgf, 3.0 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Air filter case cover...
Page 198 GENERAL CHASSIS Removing the rear fender 28 Nm (2.8 m kgf, 20 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 199 GENERAL CHASSIS Removing the rear fender 28 Nm (2.8 m kgf, 20 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 200 GENERAL CHASSIS Removing the headlight 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...
Page 201: Front Wheel
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc (except for ABS models) 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 202 FRONT WHEEL Removing the front wheel and brake disc (for ABS models) 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 203 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor For ABS models Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure.
Page 204: Removing The Front Wheel
FRONT WHEEL EAS21900 EAS21910 REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL ECA1XC1018 ECA1XC1011 NOTICE NOTICE For ABS models For ABS models • Keep any type of magnets (including mag- • Do not drop the wheel sensor rotor or sub- netic pick-up tools, magnetic screwdrivers, ject it to shocks.
Page 205: Maintenance Of The Front Wheel Sensor And Sensor Rotor (For Abs Models)
FRONT WHEEL EWA13460 WARNING Do not attempt to straighten a bent wheel ax- EAS1XC1034 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR (for ABS models) ECA1XC1006 2. Check: NOTICE • Tire • Handle the ABS components with care • Front wheel since they have been accurately adjusted.
Page 206: Assembling The Front Wheel
FRONT WHEEL Front wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LOCTITE® ECA1XC1007 NOTICE Replace the wheel sensor rotor bolts with new ones. d. If the deflection is still above specification, re- place the wheel sensor rotor. 3. Measure: ▲...
Page 207: Adjusting The Front Wheel Static Balance
FRONT WHEEL EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE • After replacing the tire, wheel or both, the front wheel static balance should be adjusted. • Adjust the front wheel static balance with the brake disc installed. 1. Remove: • Balancing weight(s) ▲...
Page 208: Installing The Front Wheel (Front Brake Disc)
FRONT WHEEL 3. Adjust: EAS22000 INSTALLING THE FRONT WHEEL (FRONT • Front wheel static balance BRAKE DISC) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 1. Install: a. Install a balancing weight “1” onto the rim ex- •...
Page 209 FRONT WHEEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the front wheel axle from the right side Distance “a” (between the front wheel sensor rotor and front and tighten it to 59 Nm (5.9 m·kgf, 43 ft·lbf).
Page 210: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel (except for ABS models) 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) •...
Page 211 REAR WHEEL Removing the rear wheel (except for ABS models) 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 212 REAR WHEEL Removing the rear wheel (for ABS models) 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 213 REAR WHEEL Removing the rear wheel (for ABS models) 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 214 REAR WHEEL Removing the rear brake disc and rear wheel drive hub 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 95 Nm (9.5 m kgf, 69 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • •...
Page 215 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Bearing Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-24...
Page 216: Removing The Rear Wheel (Disc)
REAR WHEEL EAS28760 REMOVING THE REAR WHEEL (DISC) ECA1XC1021 NOTICE (For ABS models) • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1” or rear wheel sensor rotor “2”; otherwise, the sensor or rotor may be damaged, resulting in improper performance of the ABS sys- 4.
Page 217: Checking The Rear Brake Caliper Bracket
REAR WHEEL • Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-13. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) EAS1TP1014 CHECKING THE REAR BRAKE CALIPER ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 218: Assembling The Rear Wheel
REAR WHEEL EAS22140 EAS22150 ASSEMBLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC ECA1XC1011 BALANCE NOTICE For ABS models • After replacing the tire, wheel or both, the rear • Do not drop the wheel sensor rotor or sub- wheel static balance should be adjusted. ject it to shocks.
Page 219 REAR WHEEL 3. Lubricate: • Rear wheel axle • Oil seal lips Recommended lubricant Lithium-soap-based grease 4. Install: • Rear brake disc Rear brake disc bolt 7. Adjust: 23 Nm (2.3 m·kgf, 17 ft·lbf) • Drive belt slack LOCTITE® Refer to “ADJUSTING THE DRIVE BELT SLACK”...
Page 220 REAR WHEEL 10.Measure: EWA13500 WARNING • Distance “a” Make sure the brake hose is routed properly. (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC-...
Page 221: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads (except for ABS models) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) •...
Page 222 FRONT BRAKE Removing the front brake pads (for ABS models) 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 223 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) •...
Page 224 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) •...
Page 225 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-34...
Page 226 FRONT BRAKE Removing the front brake caliper (except for ABS models) 30 Nm (3.0 m kgf, 22 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Brake fluid BRAKE SYSTEM (except for ABS models)”...
Page 227 FRONT BRAKE Removing the front brake caliper (for ABS models) 30 Nm (3.0 m kgf, 22 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC Brake fluid BRAKE SYSTEM (for ABS models)”...
Page 228 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front brake caliper retaining bolt Brake pad Brake pad shim Brake pad spring Brake pad support...
Page 229 FRONT BRAKE Removing the brake pipe/hose assemblies (for ABS models) 30 Nm (3.0 m kgf, 22 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 230: Introduction
FRONT BRAKE EAS22220 INTRODUCTION Brake disc runout limit (as mea- EWA1TP1022 sured on wheel) WARNING 0.15 mm (0.0059 in) Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 231: Replacing The Front Brake Pads
FRONT BRAKE 2. Install: • Brake pad supports • Brake pad spring • Brake pad shims (onto the brake pads) • Brake pads Always install new brake pads brake pad shims, brake pad supports and a brake pad spring as a set.
Page 232: Removing The Front Brake Caliper
FRONT BRAKE 5. Check: EAS22350 DISASSEMBLING THE FRONT BRAKE • Brake fluid level CALIPER Below the minimum level mark “a” → Add the 1. Remove: specified brake fluid to the proper level. • Brake caliper pistons “1” Refer to “CHECKING THE BRAKE FLUID •...
Page 233: Assembling The Front Brake Caliper
FRONT BRAKE Recommended brake component replace- Specified brake fluid ment schedule DOT 4 Every two years and Brake fluid whenever the brake EAS22440 INSTALLING THE FRONT BRAKE CALIPER is disassembled 1. Install: 1. Check: • Front brake caliper “1” • Brake caliper pistons “1” (temporarily) Rust/scratches/wear →...
Page 234: Removing The Front Brake Master Cylinder
FRONT BRAKE Front brake caliper retaining bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) Front brake caliper bracket bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-40. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the specified 7.
Page 235: Assembling The Front Brake Master Cylinder
FRONT BRAKE • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake master cylinder reservoir Cracks/damage → Replace. • Brake master cylinder reservoir diaphragm Damage/wear →...
Page 236 FRONT BRAKE EWA13540 EAS1XC1055 INSTALLING THE BRAKE PIPE/HOSE WARNING ASSEMBLIES (for ABS models) • Use only the designated brake fluid. Other 1. Assemble: brake fluids may cause the rubber seals to • Brake pipe/hose assembly (hydraulic unit to deteriorate, causing leakage and poor front brake caliper) “1”...
Page 237 FRONT BRAKE ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: 3.
Page 238: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Rear brake pad shim...
Page 239 REAR BRAKE Removing the rear brake master cylinder (except for ABS models) 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
Page 240 REAR BRAKE Removing the rear brake master cylinder (except for ABS models) 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
Page 241 REAR BRAKE Removing the rear brake master cylinder (for ABS models) 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • •...
Page 242 REAR BRAKE Removing the rear brake master cylinder (for ABS models) 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • •...
Page 243 REAR BRAKE Disassembling the rear brake master cylinder 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake master cylinder joint Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 244 REAR BRAKE Removing the rear brake caliper 27 Nm (2.7 m kgf, 20 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (except for ABS models)” Brake fluid on page 3-12 and “BLEEDING THE HY- DRAULIC BRAKE SYSTEM (for ABS mod-...
Page 245 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper bracket Brake pad Brake pad shim Brake pad spring...
Page 246: Introduction
REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EAS22560 INTRODUCTION DISC” on page 4-39. EWA1TP1022 WARNING Brake disc thickness limit Disc brake components rarely require disas- 5.5 mm (0.22 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...
Page 247: Removing The Rear Brake Caliper
REAR BRAKE • Brake pad shims Refer to “CHECKING THE BRAKE FLUID (onto the brake pads) LEVEL” on page 3-11. • Brake pad springs Always install new brake pads, brake pad shims and brake pad springs as a set. ▼ ▼▼▼...
Page 248: Checking The Rear Brake Caliper
REAR BRAKE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EWA1TP1006 WARNING a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the Whenever a brake caliper is disassembled, brake caliper.
Page 249: Removing The Rear Brake Master Cylinder
REAR BRAKE ECA14170 ECA13540 NOTICE NOTICE When installing the brake hose onto the Brake fluid may damage painted surfaces brake caliper “1”, make sure the brake pipe and plastic parts. Therefore, always clean up “a” touches the projection “b” on the brake any spilt brake fluid immediately.
Page 250: Checking The Rear Brake Master Cylinder
REAR BRAKE To collect any remaining brake fluid, place a The rear brake master cylinder joint installation container under the master cylinder and the end length “a” should be 101.8 mm (4.01 in). of the brake hose. EAS22750 INSTALLING THE REAR BRAKE MASTER EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER...
Page 251 REAR BRAKE • Refill with the same type of brake fluid that ECA1TP1009 NOTICE is already in the system. Mixing brake fluids When installing the brake hose onto the may result in a harmful chemical reaction, brake master cylinder, make sure the brake leading to poor brake performance.
Page 252: Abs (Anti-Lock Brake System) (For Abs Models)
ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS1XC1042 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Removing the hydraulic unit assembly and brackets 30 Nm (3.0 m kgf, 22 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • •...
Page 253 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Removing the hydraulic unit assembly and brackets 30 Nm (3.0 m kgf, 22 ft Ibf) 30 Nm (3.0 m kgf, 22 ft Ibf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) •...
Page 254 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Removing the hydraulic unit assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 255: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS1XC1013 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA1XC1024 NOTICE ECA1XC1016 Unless necessary, avoid removing and in- NOTICE stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the assembly.
Page 256 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Hydraulic unit assembly and Align the line “a” on the rubber cover with the brackets bolt edge “b” of the hydraulic unit assembly upper 23 Nm (2.3 m·kgf, 17 ft·lbf) bracket. Finger tighten the bolts, and then tighten the bolts to the specified torque starting with the bolt “1”.
Page 257 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) B. The ABS ECU coupler is not connected. 7. Fill: • Brake master cylinder reservoir • Brake fluid reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EWA13090 WARNING •...
Page 258: Hydraulic Unit Operation Tests
• Before performing the brake line routing confir- mation, make sure that no malfunctions have been detected in the ABS ECU and that the 6. Start the Yamaha diagnostic tool and display wheels are not rotating. the diagnosis mode screen.
Page 259 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.
Page 260 • The reaction-force pulsating action consists of quick pulses. • Be sure to continue operating the brake lever 6. Start the Yamaha diagnostic tool and display and brake pedal even after the pulsating action the diagnosis mode screen. has stopped.
Page 261: Checking The Abs Warning Light
12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool coupler from the ABS test coupler, and then install the protective cap. 14.Turn the main switch to “ON”.
Page 262: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 263 HANDLEBAR Removing the handlebar 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 264: Removing The Handlebar
HANDLEBAR • Turn the handlebar all the way to the left EAS22860 REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING Securely support the vehicle so that there is Align the end of the upper handlebar holder with no danger of it falling over.
Page 265 HANDLEBAR b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. There should be less than 3 mm (0.12 in) of 5.
Page 266 HANDLEBAR 10.Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Install the front brake master cylinder holder with the “UP” mark facing up. •...
Page 267: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs (except for ABS models) 23 Nm (2.3 m kgf, 17 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...
Page 268 FRONT FORK Removing the front fork legs (for ABS models) 23 Nm (2.3 m kgf, 17 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 269 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Protector Front fork cap bolt O-ring Spacer Spring seat Fork spring...
Page 270 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.
Page 271: Removing The Front Fork Legs
FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.
Page 272: Checking The Front Fork Legs
FRONT FORK ECA14200 NOTICE • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 273 2. Lubricate: Fork seal driver weight • Inner tube’s outer surface 90890-01367 Replacement hammer Recommended oil YM-A9409-7 Yamaha fork oil 10WT Fork seal driver attachment (ø41) 90890-01381 3. Install: Replacement 41 mm • Inner tube YM-A5142-2 (in the outer tube) 4.
Page 274 Quantity 547.0 cm³ (18.49 US oz, 19.29 Imp.oz) Recommended oil Yamaha fork oil 10WT 8. Install: 11.Measure: • Front fork leg oil level “a” • Oil seal clip “1” (from the top of the inner tube, with the outer...
Page 275: Installing The Front Fork Legs
FRONT FORK 2. Install: • Front fork leg “1” • Before installing the front fork cap bolt, lubri- Temporarily tighten the lower bracket pinch cate its O-ring with grease. bolts. • Temporarily tighten the front fork cap bolt. • Tighten the front fork cap bolt specified torque, when installing the front fork with upper brack- Make sure the inner tube end is flush with the top of the upper bracket.
Page 276: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the upper bracket and lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) •...
Page 277 STEERING HEAD Removing the upper bracket and lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • •...
Page 278: Removing The Lower Bracket
STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- EWA13120 WARNING ECA14270...
Page 279 STEERING HEAD Face the hole “a” in the lower bracket cap rear- Align the projection “a” on the front brake hose ward. holder with the hole “b” in the lower bracket. 3. Install: • Lower ring nut “1” • Rubber washer “2” •...
Page 280: Swingarm And Rear Shock Absorber Assemblies
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES EAS1TP1016 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Removing the swingarm and rear shock absorber assemblies 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • •...
Page 281 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Removing the swingarm and rear shock absorber assemblies 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 85 Nm (8.5 m kgf, 61 ft Ibf) •...
Page 282: Removing The Swingarm And Rear Shock Absorber Assemblies
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES EAS1TP1066 EAS23360 REMOVING THE SWINGARM AND REAR CHECKING THE SWINGARM SHOCK ABSORBER ASSEMBLIES 1. Check: 1. Stand the vehicle on a level surface. • Swingarm Bends/cracks/damage → Replace. EWA13120 WARNING 2. Check: Securely support the vehicle so that there is •...
Page 283: Disposing Of A Rear Shock Absorber (For Models Equipped With Gas Cylinders)
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES property damage or personal injury that may • Spring Damage/wear → Replace the rear shock ab- result from improper handling of the rear shock absorber and gas cylinder. sorber assembly. • Do not tamper or attempt to open the rear •...
Page 284 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Pivot shaft nut 85 Nm (8.5 m·kgf, 61 ft·lbf) 4. Install: • Rear shock absorber assembly “1” Make sure that the slot “a” in the rear shock ab- sorber assembly faces inward. (for models not equipped with gas cylinders) 5.
Page 285 BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 140 Nm (14 m kgf, 100 ft lbf) •...
Page 286 BELT DRIVE EAS23520 ECA1TP1030 REMOVING THE DRIVE BELT AND DRIVE NOTICE PULLEY • To protect the drive belt from damage, han- 1. Straighten the drive pulley nut ribs “a”. dle it with care. • The drive belt can not be bent smaller than 125 mm (4.92 in) “a”.
Page 287 BELT DRIVE Drive pulley nut 140 Nm (14 m·kgf, 100 ft·lbf) LOCTITE® • Stake the drive pulley nut at the cutouts “a” in the drive axle. • When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move.
Page 288 BELT DRIVE 4-97...
Page 289 ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE EXHAUST PIPE ............5-5 INSTALLING THE MUFFLER ..............5-6 INSTALLING THE SHIFT ARM ..............5-9 ADJUSTING THE SHIFT PEDAL.............. 5-9 INSTALLING THE HORN................5-11 REMOVING THE ENGINE ..............5-14 INSTALLING THE ENGINE..............
Page 290 CLUTCH ......................5-48 REMOVING THE PRIMARY DRIVE GEAR ..........5-53 REMOVING THE CLUTCH ..............5-53 CHECKING THE FRICTION PLATES.............5-53 CHECKING THE CLUTCH PLATES ............5-54 CHECKING THE CLUTCH SPRING PLATE...........5-54 CHECKING THE CLUTCH HOUSING ............5-54 CHECKING THE CLUTCH BOSS............5-55 CHECKING THE PRESSURE PLATE ............5-55 CHECKING THE PRIMARY DRIVE GEAR..........
Page 291 TRANSMISSION.................... 5-80 CHECKING THE SHIFT FORKS............. 5-83 CHECKING THE SHIFT DRUM ASSEMBLY..........5-83 CHECKING THE TRANSMISSION ............5-83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..5-84...
Page 292: Engine Inspection
ENGINE INSPECTION 7. Measure: EAS1TP1047 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS20710 (d). MEASURING THE COMPRESSION PRESSURE Standard compression pressure The following procedure applies to all of the cyl- (at sea level) inders.
Page 293 ENGINE INSPECTION 10.Install: • Rear cylinder right cover Refer to “ENGINE REMOVAL” on page 5-3.
Page 294: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipe 15 Nm (1.5 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
Page 295 ENGINE REMOVAL Removing the muffler and exhaust pipe 15 Nm (1.5 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 296: Installing The Exhaust Pipe
ENGINE REMOVAL EAS1TP1068 INSTALLING THE EXHAUST PIPE 1. Install: • Exhaust pipe joint • Exhaust pipe joint cover Exhaust pipe joint nut 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe joint cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Tighten the exhaust pipe joint nuts, and then in- stall the exhaust pipe joint cover and bolts.
Page 297: Installing The Muffler
ENGINE REMOVAL EAS1TP1048 INSTALLING THE MUFFLER Clamp bolt 1. Install: 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Gasket “1” (to muffler) Install the gasket with the chamfer “a”, located on an inner rim of the gasket, and the chamfer “b”, located on an outer rim of the gasket, as shown.
Page 298 ENGINE REMOVAL Removing the sidestand and drive pulley housing 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 299 ENGINE REMOVAL Removing the sidestand and drive pulley housing 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 300: Installing The Shift Arm
ENGINE REMOVAL EAS1TP1050 INSTALLING THE SHIFT ARM Make sure that the engaged thread length on 1. Install: both ends of the shift rod is 4 ridges or more. • Shift arm “1” Shift arm bolt Direction “a” 16 Nm (1.6 m·kgf, 12 ft·lbf) Installed shift rod length is increased.
Page 301 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 302: Installing The Horn
ENGINE REMOVAL EAS1TP1070 INSTALLING THE HORN 1. Install: • Horn “1” Horn bracket bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Make sure that the horn bracket “2” contacts the portion “a” of the stay on the frame. 5-11...
Page 303: Engine
ENGINE REMOVAL Removing the engine 48 Nm (4.8 m kgf, 35 ft Ibf) • • 88 Nm (8.8 m kgf, 64 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 304 ENGINE REMOVAL Removing the engine 48 Nm (4.8 m kgf, 35 ft Ibf) • • 88 Nm (8.8 m kgf, 64 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 305: Removing The Engine
ENGINE REMOVAL EAS1TP1051 REMOVING THE ENGINE 1. Remove: • Engine bracket (front upper side) “1” Before removing the engine, remove the engine bracket (front upper side) so that the cylinder head does not strike the bracket. EAS23720 INSTALLING THE ENGINE 1.
Page 306 ENGINE REMOVAL 3. Tighten: • Engine mounting nut (rear upper side) “16” • Engine mounting nut (front upper side) “17” • Engine mounting nut (rear lower side) “18” • Engine mounting nut (front lower side) “19” Engine mounting nut (rear upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (front upper...
Page 307: Camshafts
CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 308 CAMSHAFTS Removing the camshafts and rocker arms 27 Nm (2.7 m kgf, 20 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 309 CAMSHAFTS Removing the camshafts and rocker arms 27 Nm (2.7 m kgf, 20 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 310: Removing The Camshafts And Rocker Arms
CAMSHAFTS EAS1TP1052 REMOVING THE CAMSHAFTS AND ROCKER ARMS 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder head) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 311: Checking The Camshafts
CAMSHAFTS Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Remove: • Rear cylinder timing chain tensioner •...
Page 312: Checking The Camshaft Sprockets
CAMSHAFTS Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720– 1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583– 1.4622 in) Limit 36.941 mm (1.4544 in) a. 1/4 tooth Exhaust A b. Correct 42.138–42.238 mm (1.6590– 1. Timing chain roller 1.6629 in) 2.
Page 313: Checking The Timing Chain Tensioners
CAMSHAFTS • Timing chain tensioner rod “6” Rocker arm shaft outside diame- Damage/wear → Replace the defective part(s). 11.981–11.991 mm (0.4717– 0.4721 in) Limit 11.941 mm (0.4701 in) EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts.
Page 314 CAMSHAFTS 5. Install: d. Remove the wire from the timing chain. • Front cylinder camshaft sprocket ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Tighten: ▼ ▼▼▼ ▼ ▼▼▼ ▼...
Page 315 CAMSHAFTS ECA13740 • Copper washer “4” NOTICE • Timing chain tensioner cap bolt “3” Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper Timing chain tensioner cap bolt valve timing. 24 Nm (2.4 m·kgf, 17 ft·lbf) •...
Page 316: Installing The Cylinder Head Covers
CAMSHAFTS 11.Install: • Tappet covers • Rear cylinder timing chain tensioner gasket Rear cylinder side cover bolt “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Rear cylinder timing chain tensioner “2” LOCTITE® Tappet cover 10 Nm (1.0 m·kgf, 7.2 ft·lbf) To push in the timing chain tensioner rod, re- lease the lock by pushing in the one-way cam 2.
Page 317: Cylinder Heads
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 15 Nm (1.5 m kgf, 11 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • 25 Nm (2.5 m kgf, 18 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) •...
Page 318: Removing The Cylinder Heads
CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the cylinder head nuts in the proper se- quence as shown. • Loosen each cylinder head nut 1/2 of a turn at a time.
Page 319 CYLINDER HEADS Cylinder head nut 1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) 2nd: 25 Nm (2.5 m·kgf, 18 ft·lbf) Final: 65 Nm (6.5 m·kgf, 47 ft·lbf) Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Lubricate the cylinder head nuts and washers with engine oil.
Page 320 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-26. Valve cotter Upper spring seat Valve spring Intake valve...
Page 321: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
Page 322 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 12.7–13.1 mm (0.500–0.515 in) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...
Page 323: Checking The Valve Seats
VALVES AND VALVE SPRINGS 4. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear → Grind the valve face. (from the valve face and valve seat) • Valve stem end 2. Check: Mushroom shape or diameter larger than the •...
Page 324: Checking The Valve Springs
VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 325: Installing The Valves
VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 42.43 mm (1.67 in) 2.5 °/1.9 mm (0.07 in) Limit Spring tilt (exhaust) 40.31 mm (1.59 in) 2.5 °/1.9 mm (0.07 in) Free length (exhaust) 42.43 mm (1.67 in) Limit 40.31 mm (1.59 in) EAS24340 INSTALLING THE VALVES...
Page 326 VALVES AND VALVE SPRINGS Install the valve cotters by compressing the valve spring with the valve spring compressor “1” and the valve spring compressor attachment “2”. Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- 4. Install: ment • Lower spring seat “1” 90890-01243 Valve spring compressor adapt- •...
Page 327 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-26. Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin Piston Top ring...
Page 328: Cylinders And Pistons
CYLINDERS AND PISTONS EAS24380 REMOVING THE PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons. over the piston crown. 1.
Page 329: Checking The Piston Rings
CYLINDERS AND PISTONS f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...
Page 330: Checking The Piston Pins
CYLINDERS AND PISTONS Piston pin outside diameter 20.991–21.000 mm (0.8264– 0.8268 in) Limit 20.971 mm (0.8256 in) a. 10 mm (0.39 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. 3. Measure: The oil ring expander spacer end gap cannot be •...
Page 331: Installing The Pistons And Cylinders
CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: • Top ring “1” • 2nd ring “2” • Oil ring expander “3” • Lower oil ring rail “4” •...
Page 332 CYLINDERS AND PISTONS 6. Install: • Cylinder “1” • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity. 5-41...
Page 333: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (12) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 334 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (12) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 335 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 24 Nm (2.4 m kgf, 17 ft Ibf) • • 90 Nm (9.0 m kgf, 65 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Starter clutch idle gear 2 shaft...
Page 336: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the projection on the generator rotor.
Page 337: Installing The Starter Clutch
While holding the generator rotor “2” with the sheave holder “3”, tighten the starter clutch bolts. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-46...
Page 338: Installing The Generator Cover
GENERATOR AND STARTER CLUTCH EAS1TP1054 INSTALLING THE GENERATOR COVER 1. Install: Generator cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illustration. 5-47...
Page 339: Clutch
CLUTCH EAS25060 CLUTCH Removing the primary drive gear 100 Nm (10 m kgf, 72 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 340 CLUTCH Removing the primary drive gear 100 Nm (10 m kgf, 72 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 341 CLUTCH Removing the pull lever shaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing Oil seal retainer Oil seal For installation, reverse the removal proce- dure.
Page 342 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Bearing...
Page 343 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump drive sprocket Thrust washer 2 For installation, reverse the removal proce- dure.
Page 344: Removing The Primary Drive Gear
CLUTCH EAS25090 REMOVING THE PRIMARY DRIVE GEAR While holding the clutch boss “2” with the univer- 1. Straighten the lock washer tab. sal clutch holder “3”, loosen the clutch boss nut. 2. Remove: • Primary drive gear nut “1” • Lock washer “2” Universal clutch holder 90890-04086 YM-91042...
Page 345: Checking The Clutch Plates
CLUTCH Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.80 mm (0.110 in) Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage →...
Page 346: Checking The Clutch Boss
CLUTCH EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set.
Page 347 CLUTCH • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil. • Install the conical spring washer with the “OUT” mark “a” facing out. • While holding the clutch boss with the univer- sal clutch holder “4”, tighten the clutch boss nut.
Page 348 CLUTCH • Starter motor lead and rear brake light switch lead holder Clutch cover bolt “1”–“13”, “15” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cover bolt (with washer) “14” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten the bolts “a” and “b”, and then 6.
Page 349: Installing The Primary Drive Gear
CLUTCH EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1. Install: • Primary drive gear “1” • Spacer “2” • Lock washer “3” • Primary drive gear nut Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf) • Make sure that the shorter side of the primary drive gear is facing outward.
Page 350: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-94. Shift arm Refer to “ENGINE REMOVAL”...
Page 351: Checking The Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
Page 352: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 353 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Armature assembly Starter motor yoke Gasket Starter motor rear cover Brush set assembly...
Page 354: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. ▲...
Page 355: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Bearing Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush set assembly 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a”...
Page 356: Crankcase
CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
Page 357 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 358 CRANKCASE Separating the crankcase 15 Nm (1.5 m kgf, 11 ft Ibf) • • (19) 15 Nm (1.5 m kgf, 11 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil baffle plate 1 Left crankcase Dowel pin Joint pipe O-ring Oil baffle plate 2 Gasket...
Page 359 CRANKCASE Removing the oil seal and bearings Order Job/Parts to remove Q’ty Remarks Oil pump assembly Refer to “OIL PUMP” on page 5-72. Crankshaft Refer to “CRANKSHAFT” on page 5-75. Transmission Refer to “TRANSMISSION” on page 5-80. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.
Page 360: Disassembling The Crankcase
CRANKCASE EAS25560 EAS25580 DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE 1. Remove: 1. Thoroughly wash the crankcase halves in a • Crankcase bolts mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Loosen each bolt 1/4 of a turn at a time, in stag- 3.
Page 361: Assembling The Crankcase
1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 • M6 × 120 mm bolts: “a” 90890-85505 (Three Bond No.1215®) • Oil baffle plate 1 bolts: “b”...
Page 362 CRANKCASE 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-71...
Page 363: Oil Pump
OIL PUMP EAS24910 OIL PUMP Removing the oil pump assembly 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 364: Checking The Oil Pump
OIL PUMP EAS24960 EAS24970 CHECKING THE OIL PUMP CHECKING THE RELIEF VALVE 1. Check: 1. Check: • Oil pump housing • Relief valve body “1” Cracks/damage/wear → Replace the oil • Relief valve “2” pump assembly. • Spring “3” 2. Measure: •...
Page 365: Installing The Oil Pump Assembly
OIL PUMP When installing the inner rotor, align the pin in the impeller shaft with the grooves “a” in the in- ner rotor. Oil pump housing screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-73.
Page 366: Crankshaft
CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.
Page 367: Removing The Connecting Rods
CRANKSHAFT The following procedure applies to all of the EAS26010 REMOVING THE CONNECTING RODS connecting rods. 1. Remove: ECA13930 • Connecting rod caps “1” NOTICE • Connecting rods Do not interchange the big end bearings and • Big end bearings connecting rods.
Page 368 CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. e. Tighten the connecting rod bolts. Refer to “INSTALLING THE CONNECTING RODS” on page 5-78. f. Remove the connecting rod and big end bearings.
Page 369: Installing The Connecting Rods
CRANKSHAFT 6. Measure: Recommended lubricant • Crankshaft journal bearing inside diameter Engine oil “a” Out of specification → Replace the crank- 3. Install: case assembly. • Big end bearings • Connecting rods Measure the inside diameter of each crankshaft • Connecting rod caps journal bearing at two places.
Page 370: Installing The Crankshaft Assembly
CRANKSHAFT EAS26210 INSTALLING THE CRANKSHAFT Tighten the connecting rod bolts using the fol- ASSEMBLY lowing procedure. 1. Install: • Crankshaft assembly a. Tighten the connecting rod bolts to specifica- ECA1TP1023 tion with a torque wrench. NOTICE To avoid scratching the crankshaft and to Connecting rod bolt (1st) ease the installation procedure, lubricate 15 Nm (1.5 m·kgf, 11 ft·lbf)
Page 371 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
Page 372 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 4th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
Page 373 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle...
Page 374: Transmission
TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: •...
Page 375: Assembling The Main Axle And Drive Axle
TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer in the Cracks/damage/rounded edges → Replace groove “a”...
Page 376 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply molybdenum disulfide grease to each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-85...
Page 377: Fuel System
FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-3 REMOVING THE FUEL PUMP ..............6-3 CHECKING THE FUEL PUMP BODY............6-3 CHECKING THE ROLLOVER VALVE ............6-3 INSTALLING THE FUEL PUMP..............6-4 INSTALLING THE FUEL SENDER ............6-5 THROTTLE BODIES ..................6-6 CHECKING THE INJECTORS ..............6-9 INSTALLING THE INJECTORS ..............6-9 CHECKING THE THROTTLE BODIES.............6-9 CHECKING THE INTAKE MANIFOLD JOINTS ........
Page 378 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 379 FUEL TANK Removing the rollover valve 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Rectifier/regulator coupler Disconnect.
Page 380: Removing The Fuel Tank
FUEL TANK EAS1TP1036 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel tank ECA1TP1024 NOTICE Make sure that the fuel tank does not strike the meter assembly when removing it. EAS1TP1037 REMOVING THE FUEL PUMP 1.
Page 381: Installing The Fuel Pump
FUEL TANK • The rollover valve must be in an upright posi- tion when checking the airflow. EAS1TP1039 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump • Gasket Fuel pump bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) 2. Install: ECA1TP1027 NOTICE •...
Page 382: Installing The Fuel Sender
FUEL TANK A. Connection to fuel pump and fuel filter B. Connection between fuel hoses EAS1TP1040 INSTALLING THE FUEL SENDER 1. Install: • Fuel sender • O-ring Fuel sender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Position the fuel sender coupler “1” between the guides “a”...
Page 383 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 384 THROTTLE BODIES Removing the intake manifold assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 385: Throttle Bodies
THROTTLE BODIES Disassembling the intake manifold 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Pressure regulator...
Page 386: Checking The Injectors
THROTTLE BODIES EAS26980 EAS26990 CHECKING THE INJECTORS CHECKING THE THROTTLE BODIES EWA1TP1015 1. Check: WARNING • Throttle bodies Cracks/damage → Replace the throttle bod- • Check the injectors in a well-ventilated area free of combustible materials. Make sure ies as a set. that there is no smoking or use of electric 2.
Page 387: Adjusting The Throttle Position Sensor
THROTTLE BODIES Vacuum/pressure pump gauge The vacuum pressure should not exceed 100 kPa (760 mmHg). 90890-06756 Mityvac brake bleeding tool • Increase the vacuum pressure → YS-42423 Fuel pressure is decreased Pressure gauge • Decrease the vacuum pressure → 90890-03153 Fuel pressure is increased YU-03153 Fuel pressure adapter...
Page 388: Removing The Intake Manifold Assembly
THROTTLE BODIES Throttle position sensor screw Be sure to fit the projection “b” on the intake 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) manifold assembly between the projections “c” on the rear cylinder intake manifold joint. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...
Page 389: Electrical System
CIRCUIT DIAGRAM (except for ABS models) ........7-39 CIRCUIT DIAGRAM (for ABS models)............7-41 ECU SELF-DIAGNOSTIC FUNCTION............7-43 TROUBLESHOOTING METHOD............7-44 YAMAHA DIAGNOSTIC TOOL ...............7-45 TROUBLESHOOTING DETAILS ............7-48 FUEL PUMP SYSTEM...................7-91 CIRCUIT DIAGRAM (except for ABS models) ........7-91 CIRCUIT DIAGRAM (for ABS models)............7-93...
Page 390 IMMOBILIZER SYSTEM................7-97 CIRCUIT DIAGRAM (except for ABS models) ........7-97 CIRCUIT DIAGRAM (for ABS models)............7-99 GENERAL INFORMATION ..............7-101 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS.................7-101 TROUBLESHOOTING ................7-105 SELF-DIAGNOSIS FAULT CODE INDICATION........7-106 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) ......7-109 CIRCUIT DIAGRAM ................7-109 ABS COMPONENTS CHART ...............7-111 ABS COUPLER LOCATION CHART ............7-113...
Page 391 ELECTRICAL COMPONENTS..............7-147 CHECKING THE SWITCHES ...............7-151 CHECKING THE BULBS AND BULB SOCKETS .........7-154 CHECKING THE FUSES ..............7-155 CHECKING AND CHARGING THE BATTERY........7-156 CHECKING THE RELAYS ..............7-159 CHECKING THE TURN SIGNAL/HAZARD RELAY......7-160 CHECKING THE RELAY UNIT (DIODE) ..........7-161 CHECKING THE IGNITION SPARK GAP..........7-162 CHECKING THE SPARK PLUG CAPS..........7-162 CHECKING THE IGNITION COILS............7-162 CHECKING THE CRANKSHAFT POSITION SENSOR......7-163...
Page 392: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS1XC1043 CIRCUIT DIAGRAM (except for ABS models)
Page 393 IGNITION SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 7. Fuel injection system fuse 10.Ignition fuse 16.Relay unit 19.Neutral switch 20.Sidestand switch 25.Crankshaft position sensor 26.Lean angle sensor 31.ECU (engine control unit) 32.Front cylinder ignition coil 33.Spark plug 34.Rear cylinder ignition coil 50.Joint coupler...
Page 394: Circuit Diagram (For Abs Models)
IGNITION SYSTEM EAS1XC1044 CIRCUIT DIAGRAM (for ABS models)
Page 395 IGNITION SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 10.Fuel injection system fuse 13.Joint coupler 17.Ignition fuse 24.Relay unit 27.Neutral switch 28.Sidestand switch 32.Crankshaft position sensor 33.Lean angle sensor 38.ECU (engine control unit) 39.Front cylinder ignition coil 40.Spark plug 41.Rear cylinder ignition coil 78.Engine stop switch...
Page 396: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 397: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank 4. Rear cylinder right cover 5. Air duct 6.
Page 398 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 7-151. OK ↓ NG → 9. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE •...
Page 399 IGNITION SYSTEM...
Page 400: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS1XC1045 CIRCUIT DIAGRAM (except for ABS models)
Page 401 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 8. Starter relay 9. Starter motor 10.Ignition fuse 16.Relay unit 17.Starting circuit cut-off relay 19.Neutral switch 20.Sidestand switch 50.Joint coupler 58.Clutch switch 71.Engine stop switch 72.Start switch A.
Page 402: Circuit Diagram (For Abs Models)
ELECTRIC STARTING SYSTEM EAS1XC1046 CIRCUIT DIAGRAM (for ABS models) 7-11...
Page 403 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 8. Starter relay 9. Starter motor 13.Joint coupler 17.Ignition fuse 24.Relay unit 25.Starting circuit cut-off relay 27.Neutral switch 28.Sidestand switch 65.Clutch switch 78.Engine stop switch 79.Start switch A.
Page 404: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 405: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank 4. Air duct 5. Drive pulley NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
Page 406 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 7-151. OK ↓ NG → 9. Check the engine stop switch. • The engine stop switch is faulty. Refer to “CHECKING THE •...
Page 407 ELECTRIC STARTING SYSTEM 7-16...
Page 408: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS1XC1047 CIRCUIT DIAGRAM (except for ABS models) 7-17...
Page 409 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 5. Battery A. Wire harness B. Negative battery sub-wire harness 7-18...
Page 410: Circuit Diagram (For Abs Models)
CHARGING SYSTEM EAS1XC1048 CIRCUIT DIAGRAM (for ABS models) 7-19...
Page 411 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 5. Battery A. Wire harness B. Negative battery sub-wire harness 7-20...
Page 412: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Air duct NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 413 CHARGING SYSTEM 7-22...
Page 414: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS1XC1049 CIRCUIT DIAGRAM (except for ABS models) 7-23...
Page 415 LIGHTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 7. Fuel injection system fuse 10.Ignition fuse 11.Signaling system fuse 14.Headlight fuse 31.ECU (engine control unit) 41.Multi-function meter 45.Meter light 46.High beam indicator light 50.Joint coupler 52.Headlight relay 54.Dimmer switch 55.Pass switch 61.Headlight 62.Auxiliary light...
Page 416: Circuit Diagram (For Abs Models)
LIGHTING SYSTEM EAS1XC1050 CIRCUIT DIAGRAM (for ABS models) 7-25...
Page 417 LIGHTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 10.Fuel injection system fuse 13.Joint coupler 17.Ignition fuse 19.Signaling system fuse 22.Headlight fuse 38.ECU (engine control unit) 48.Multi-function meter 52.Meter light 54.High beam indicator light 59.Headlight relay 61.Dimmer switch 62.Pass switch 68.Headlight 69.Auxiliary light 74.License plate light...
Page 418: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, meter light or auxiliary light. 1. Left side cover 2. Rider seat 3. Fuel tank 4. Tail/brake light NG → 1.
Page 419 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har- cept for ABS models)” on page 7-23 ness. and “CIRCUIT DIAGRAM (for ABS models)” on page 7-25. OK ↓...
Page 420: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS1XC1017 CIRCUIT DIAGRAM (except for ABS models) 7-29...
Page 421 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 7. Fuel injection system fuse 10.Ignition fuse 11.Signaling system fuse 12.Hazard lighting fuse 16.Relay unit 19.Neutral switch 21.Speed sensor 31.ECU (engine control unit) 38.Oil level switch 40.Neutral indicator light 41.Multi-function meter 43.Oil level warning light 44.Fuel level warning light...
Page 422: Circuit Diagram (For Abs Models)
SIGNALING SYSTEM EAS1XC1018 CIRCUIT DIAGRAM (for ABS models) 7-31...
Page 423 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 10.Fuel injection system fuse 12.ABS ECU (electronic control unit) 13.Joint coupler 15.Rear wheel sensor 17.Ignition fuse 18.ABS ECU fuse 19.Signaling system fuse 20.Hazard lighting fuse 24.Relay unit 27.Neutral switch 38.ECU (engine control unit) 45.Oil level switch...
Page 424: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 425 SIGNALING SYSTEM Checking the signaling system The horn fails to sound. NG → 1. Check the horn switch. • The horn switch is faulty. Refer to “CHECKING THE • Replace the left handlebar switch. SWITCHES” on page 7-151. OK ↓ NG →...
Page 426 SIGNALING SYSTEM NG → 3. Check the hazard switch. • The hazard switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 7-151. OK ↓ NG → 4. Check the turn signal/hazard relay. Refer to “CHECKING THE RE- Replace the turn signal/hazard relay.
Page 427 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM (ex- Properly connect or replace the wire har- cept for ABS models)” on page 7-29 ness. and “CIRCUIT DIAGRAM (for ABS models)” on page 7-31. OK ↓...
Page 428 SIGNALING SYSTEM NG → 2. Check the entire wheel sensor wir- Properly connect or replace the wire har- ing. ness. Refer to TIP. OK ↓ Replace the hydraulic unit assembly, ECU or meter assembly. Replace the wire harness if there is an open or short circuit. •...
Page 429 SIGNALING SYSTEM 7-38...
Page 430: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS1XC1019 CIRCUIT DIAGRAM (except for ABS models) 7-39...
Page 431 24.Intake air temperature sensor 25.Crankshaft position sensor 26.Lean angle sensor 27.Throttle position sensor 28.Intake air pressure sensor 29.ISC (idle speed control) unit 30.Yamaha diagnostic tool coupler 31.ECU (engine control unit) 32.Front cylinder ignition coil 33.Spark plug 34.Rear cylinder ignition coil 35.Front cylinder injector 36.Rear cylinder injector...
Page 432: Circuit Diagram (For Abs Models)
FUEL INJECTION SYSTEM EAS1XC1020 CIRCUIT DIAGRAM (for ABS models) 7-41...
Page 433 31.Intake air temperature sensor 32.Crankshaft position sensor 33.Lean angle sensor 34.Throttle position sensor 35.Intake air pressure sensor 36.ISC (idle speed control) unit 37.Yamaha diagnostic tool coupler 38.ECU (engine control unit) 39.Front cylinder ignition coil 40.Spark plug 41.Rear cylinder ignition coil 42.Front cylinder injector 43.Rear cylinder injector...
Page 434: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 435: Troubleshooting Method
FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS30580 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sensors engine trouble warning light comes on. and actuators in the diagnostic mode.
Page 436: Yamaha Diagnostic Tool
Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.
Page 437 FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Malfunction mode) Malfunction results are displayed in the top part of the window area. 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed.
Page 438 FUEL INJECTION SYSTEM 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9.
Page 439: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the multi-function meter dis- play. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service of the malfunctioning part has been completed, reset the multi-function meter display according to the reinstatement method.
Page 440 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Installed condition of crank- Improperly installed sensor Crank the engine. → Reinstall or replace the shaft position sensor. Fault code number is not dis- played →...
Page 441 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 442 FUEL INJECTION SYSTEM If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 443 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Throttle position sensor signal Indicated • 14–20 (fully closed position) • 92–102 (fully open position) •...
Page 444 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position Check throttle position sen- Turn the main switch to “ON”. sensor. sor signal. Fault code number is not dis- played → Service is finished. Execute the diagnostic mode.
Page 445 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/black Item lead of the ECU (engine control unit) is detected. Improperly connected → Connection of main switch Turn the main switch to “ON”, coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or replace the wire har-...
Page 446 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of intake air tem- Turn the main switch to “ON”. perature sensor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 447 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air tempera- Execute the diagnostic Turn the main switch to “ON”. ture sensor. mode. (Code No. 05) Fault code number is not dis- played →...
Page 448 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Improperly connected → Connection of ECU coupler. Start the engine, warm it up, Check the locking condition Connect the coupler secure- and then race it, or execute of the coupler.
Page 449 FUEL INJECTION SYSTEM Fault code No. Item Engine temperature sensor: open or short circuit detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of engine tem- Turn the main switch to “ON”. perature sensor coupler.
Page 450 Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No. Actuates the front cylinder ignition coil five times at one-second in- tervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. 7-59...
Page 451 FUEL INJECTION SYSTEM Fault code No. Front cylinder ignition coil: open or short circuit detected in Item the primary lead of the front cylinder ignition coil. Check that a spark is generated five times. Procedure • Connect an ignition checker. Probable cause of mal- Confirmation of service Item...
Page 452 Actuates the rear cylinder ignition coil five times at one-second in- tervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
Page 453 3 times and takes approximately 4 seconds each Actuation time. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates.
Page 454 3 times and takes approximately 4 seconds each Actuation time. The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen comes on during the operation. Procedure The ISC unit vibrates when the ISC valve operates.
Page 455 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). Improperly connected → Connection of ISC (idle Execute the diagnostic speed control) coupler.
Page 456 Actuates the front cylinder injector five times at one-second inter- vals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated. Check that front cylinder injector is actuated five times by listening Procedure for the operating sound.
Page 457 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Improperly connected → Connection of front cylinder Execute the diagnostic injector and/or rear cylinder Connect the coupler secure- mode. (Code Nos. 36, 37) No operating sound → Go to injector coupler.
Page 458 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Lean angle sensor output voltage Indicated • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 45 de- Procedure grees.
Page 459 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Fail-safe system Able to start engine Able to drive vehicle...
Page 460 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected →...
Page 461 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle...
Page 462 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected →...
Page 463 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction →...
Page 464 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase →...
Page 465 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected →...
Page 466 FUEL INJECTION SYSTEM Fault code No. 42 (Except for ABS models) Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU.
Page 467 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected →...
Page 468 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU.
Page 469 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase →...
Page 470 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Open or short circuit →...
Page 471 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Delete the fault code.
Page 472 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Clutch lever adjustment.
Page 473 FUEL INJECTION SYSTEM Fault code No. 42 (For ABS models) Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Wire harness continuity.
Page 474 Actuation (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on.)
Page 475 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Defective relay unit. Execute the diagnostic Start the engine and let it idle mode. (Code No. 09) for approximately 5 seconds. Fuel system voltage is be- Fault code number is not dis- low 3 V →...
Page 476 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Indicated — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system.
Page 477 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU (engine control unit) internal malfunction (output signal Item error): signals cannot be transmitted between the ECU and the multi-function meter. Improperly connected → Connection of meter assem- Turn the main switch to “ON”. bly coupler.
Page 478 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU (engine control unit) internal malfunction (output signal Item error): no signals are received from the ECU within the speci- fied duration. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Fault code number is not dis-...
Page 479 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU (engine control unit) internal malfunction (output signal Item error): data from the ECU cannot be received correctly. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness.
Page 480 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (engine control unit) internal malfunction (input signal er- Item ror): non-registered data has been received from the meter. Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”. Fault code number is not dis- played →...
Page 481 FUEL INJECTION SYSTEM 7-90...
Page 482 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS1XC1051 CIRCUIT DIAGRAM (except for ABS models) 7-91...
Page 483 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 5. Battery 7. Fuel injection system fuse 10.Ignition fuse 16.Relay unit 18.Fuel pump relay 31.ECU (engine control unit) 37.Fuel pump 50.Joint coupler 71.Engine stop switch A. Wire harness B. Negative battery sub-wire harness 7-92...
Page 484 FUEL PUMP SYSTEM EAS1XC1052 CIRCUIT DIAGRAM (for ABS models) 7-93...
Page 485 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 5. Battery 10.Fuel injection system fuse 13.Joint coupler 17.Ignition fuse 24.Relay unit 26.Fuel pump relay 38.ECU (engine control unit) 44.Fuel pump 78.Engine stop switch A. Wire harness B. Negative battery sub-wire harness 7-94...
Page 486 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
Page 487 FUEL PUMP SYSTEM 7-96...
Page 488 IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS1XC1053 CIRCUIT DIAGRAM (except for ABS models) 7-97...
Page 489 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 5. Battery 7. Fuel injection system fuse 10.Ignition fuse 13.Backup fuse 15.Immobilizer unit 31.ECU (engine control unit) 41.Multi-function meter 47.Immobilizer system indicator light 50.Joint coupler A. Wire harness B. Negative battery sub-wire harness 7-98...
Page 490 IMMOBILIZER SYSTEM EAS1XC1054 CIRCUIT DIAGRAM (for ABS models) 7-99...
Page 491 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 5. Battery 10.Fuel injection system fuse 13.Joint coupler 17.Ignition fuse 21.Backup fuse 23.Immobilizer unit 38.ECU (engine control unit) 48.Multi-function meter 55.Immobilizer system indicator light A. Wire harness B. Negative battery sub-wire harness 7-100...
Page 492 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...
Page 493 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
Page 494 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
Page 495 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.
Page 496 IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, fuel injection system and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 497 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the fault code number is indicated in the LCD display of meter as- sembly and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code.
Page 498 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code Unidentified code is Noise interference or 1. Check the wire received. disconnected lead/ca- harness and ble. connector. 2. Replace the main switch/im- mobilizer unit. 3. Replace the ECU. Immobilizer system indicator light fault code indication Units of 10: Cycles of on for 1 second and off for 1.5 seconds.
Page 499 IMMOBILIZER SYSTEM 7-108...
Page 500 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS1XC1036 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS27730 CIRCUIT DIAGRAM 7-109...
Page 501 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 7. ABS motor fuse 11.ABS solenoid fuse 12.ABS ECU (electronic control unit) 13.Joint coupler 14.Front wheel sensor 15.Rear wheel sensor 16.ABS test coupler 17.Ignition fuse 18.ABS ECU fuse 19.Signaling system fuse...
Page 502 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS27740 ABS COMPONENTS CHART 2 3 4 7-111...
Page 503 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) 1. ABS motor fuse 2. ABS test coupler 3. ABS ECU fuse 4. ABS solenoid fuse 5. Hydraulic unit assembly 6. ABS warning light 7. Front brake caliper 8. Front wheel sensor 9. Front wheel sensor rotor 10.
Page 504 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) EAS27750 ABS COUPLER LOCATION CHART Ch Dg Sb/W Y/L Y/G P/W W G (Gy) W Gy W Gy W/R W L/R L/B W/L G/B W/Y Y Sb P Br/W L/R L/B B/Y B/W 7-113...
Page 505 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS test coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 7-114...
Page 506 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 7-119. For troubleshooting items other than the following items, follow the normal service method.
Page 507 Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
Page 508 The main fuse is blown. • The meter assembly circuit is • defective. The connection with the Yamaha • [A-3] The ABS warning light comes diagnostic tool is defective. Cannot communicate Return to [A]. The ABS ECU fuse is blown.
Page 509 EAS1XC1007 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler. If the Yamaha diagnostic tool cannot com- municate with the vehicle, perform the following steps. For information about connecting the Yamaha diagnostic tool, refer to “[B-2] DIAGNOSIS USING THE FAULT CODES” on page 7-119.
Page 510 5. The hydraulic unit assembly is defective. EAS1XC1008 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • Fault code number is displayed. [B-2] •...
Page 511 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation. 7-120...
Page 512 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Operation of the Yamaha diagnostic tool (Fault diagnosis mode) Malfunction results are displayed in the top part of the window area. Hydraulic unit assembly Detected Power is not supplied to the ABS motor.
Page 513 The diagnosis codes related to the detected malfunction are displayed. Fault code table The details of the fault codes displayed using the Yamaha diagnostic tool are shown in the following table. Refer to this table when checking the vehicle. Delete the fault codes when the service is finished. [B-3] •...
Page 514 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code Item Symptom Check point Rear wheel sensor (ab- Rear wheel sensor signal • Foreign material ad- normal pulse period) is not received properly. hered around the rear (The pulse period is ab- wheel sensor normal while the vehicle is •...
Page 515 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code Item Symptom Check point Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the rear (Missing pulses are de- wheel sensor tected in the signal while •...
Page 516 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code Item Symptom Check point Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse (abnormal ABS motor the motor circuit in the hy- • Defective coupler be- power supply) draulic unit assembly.
Page 517 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code Item Symptom Check point Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad- ing pulses) is not received properly. hered around the rear (Missing pulses are de- wheel sensor tected in the signal while •...
Page 518 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code Item Symptom Check point Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly supply) the hydraulic unit assem- bly. Front wheel sensor power Power voltage supplied •...
Page 519 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are Symptom not received or are received intermittently while the vehicle is traveling.) Item/components and probable Order...
Page 520 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Foreign material adhered around the...
Page 521 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause Defective sensor rotor or incorrect in-...
Page 522 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Item/components and probable Order Check or maintenance job cause Open or short circuit in the wire har- •...
Page 523 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Item/components and probable Order Check or maintenance job cause Defective coupler between the rear •...
Page 524 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause...
Page 525 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause...
Page 526 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Brake light switch or tail/brake light Brake light signal is not received properly while the vehicle is Symptom traveling (brake light circuit, or front or rear brake light switch circuit).
Page 527 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Hydraulic unit assembly (abnormal ABS solenoid power sup- Item ply) Power is not supplied to the solenoid circuit in the hydraulic Symptom unit assembly. Item/components and probable Order Check or maintenance job cause Defective hydraulic unit assembly If the above items were performed and no malfunc-...
Page 528 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit Symptom assembly. Item/components and probable Order Check or maintenance job cause Open or short circuit in the wire har- •...
Page 529 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the front wheel sensor are received intermittent- ly while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
Page 530 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. (For fault code No. 42) Symptom •...
Page 531 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing Symptom pulses are detected in the signal while the vehicle is traveling.) Item/components and probable Order Check or maintenance job cause...
Page 532 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Vehicle system power supply (voltage of ABS ECU power sup- Item ply is low) Power voltage supplied to the ABS ECU in the hydraulic unit Symptom assembly is too low. Item/components and probable Order Check or maintenance job...
Page 533 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS mo- Item tor power supply circuits) Abnormality is detected in the solenoid or motor power supply Symptom circuit in the hydraulic unit assembly. Item/components and probable Order Check or maintenance job...
Page 534 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Front wheel sensor power supply (voltage of power supply is Item low) Power voltage supplied from the ABS ECU to the front wheel Symptom sensor is too low. Item/components and probable Order Check or maintenance job cause...
Page 535 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) Fault code No. Rear wheel sensor power supply (voltage of power supply is Item low) Power voltage supplied from the ABS ECU to the rear wheel Symptom sensor is too low. Item/components and probable Order Check or maintenance job cause...
Page 536 After the deletion procedure is finished, make sure that all of the fault codes displayed using the Yamaha diagnostic tool have been deleted. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the ABS test coupler (4P). EAS1XC1011 [C-1] FINAL CHECK Check the vehicle and finish the service according to the following procedures.
Page 537 ABS (ANTI-LOCK BRAKE SYSTEM) (for ABS models) 7-146...
Page 538 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-147...
Page 539 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Front cylinder ignition coil 4. Rear cylinder ignition coil 5. ABS ECU (electronic control unit) (for ABS models) 6. Turn signal/hazard relay 7. ECU (engine control unit) 8.
Page 540 ELECTRICAL COMPONENTS 7-149...
Page 541 ELECTRICAL COMPONENTS 1. Main switch/immobilizer unit 2. Throttle position sensor 3. Relay unit 4. Battery 5. Lean angle sensor 6. Headlight relay 7. Starter relay 8. ABS motor fuse (for ABS models) 9. Fuel injection system fuse (except for ABS models) 10.
Page 542 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/R Dg Br/W Ch Br/R G R/Y P Br Br/W Ch B/W Br/B B/R R/W Y/G B/Y Dg Br/B Ch Br Y 7-151...
Page 543 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Reset switch 4. Select switch 5. Engine stop switch 6. Start switch 7. Hazard switch 8. Rear brake light switch 9. Neutral switch 10. Sidestand switch 11. Dimmer switch 12.
Page 544 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 545 ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EWA13320 WARNING Do not check any of the lights that use LEDs. Since the headlight bulb gets extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from the bulb until it has cooled down.
Page 546 ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 547 ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
Page 548 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
Page 549 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.
Page 550 ELECTRICAL COMPONENTS Recommended lubricant Result Dielectric grease Continuity (between “3” and “4”) 10.Install: • Battery cover Relay unit (starting circuit cut-off relay) • ECU bracket • Rider seat • Left side cover Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS L/W.L B/R L/W R/L...
Page 551 ELECTRICAL COMPONENTS Headlight relay Br/W b. Turn the main switch to “ON”. c. Measure the turn signal/hazard relay input 1. Positive battery terminal voltage. 2. Negative battery terminal 3. Positive tester probe ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 552 ELECTRICAL COMPONENTS EAS1TP1063 CHECKING THE RELAY UNIT (DIODE) Continuity Positive tester probe → sky blue Relay unit (diode) “1” Negative tester probe → 1. Check: • Relay unit (diode) black/yellow “2” Out of specification → Replace. No continuity Positive tester probe → Pocket tester black/yellow “2”...
Page 553 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Resistance d. Check the relay unit (diode) for no continuity. 7.5–12.5 kΩ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS1TP1005 ▼...
Page 554 ELECTRICAL COMPONENTS 2. Check: • Crankshaft position sensor resistance Out of specification → Replace the crank- shaft position sensor/stator assembly. Crankshaft position sensor resis- tance 248–372 Ω ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 555 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness– lean angle sensor (6P) 90890-03209 YU-03209 • Positive tester probe → b. Check the starter motor operation. yellow/green (wire harness color) • Negative tester probe → ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 556 ELECTRICAL COMPONENTS EAS1TP1008 CHECKING THE OIL LEVEL SWITCH 1. Drain: • Engine oil 2. Remove: • Oil level switch (from the crankcase) 3. Check: B B B • Oil level switch resistance Out of specification → Replace the oil level switch.
Page 557 ELECTRICAL COMPONENTS Warning light flashes eight times, then goes EAS1TP1009 CHECKING THE FUEL SENDER off for three seconds in a repeated cycle (mal- 1. Disconnect: function detected in fuel sender or thermistor) • Fuel sender coupler → Replace the fuel sender. (from the wire harness) 2.
Page 558 ELECTRICAL COMPONENTS b. Connect the pocket tester (DC 20 V) to the Engine temperature sensor resis- speed sensor coupler (wire harness side) as tance shown. 2.63–2.78 kΩ at 20 °C (68 °F) 210–221 Ω at 100 °C (212 °F) Pocket tester 90890-03112 ▼...
Page 559 ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C Test harness S– pressure sensor 5S7 (3P) • Positive tester probe → 90890-03211 blue “1” YU-03211 • Negative tester probe → black/blue “2” • Positive tester probe → pink (wire harness color) •...
Page 560 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Make sure that the intake air temperature sensor terminals do not get wet. c. Measure the fuel injector resistance. ▲...
Page 561: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................8-2 POOR BRAKING PERFORMANCE............8-3 FAULTY FRONT FORK LEGS..............8-3 UNSTABLE HANDLING ................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........
Page 562: Troubleshooting
TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 563: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
Page 564: Poor Braking Performance
TROUBLESHOOTING • Incorrect oil viscosity • Incorrect oil level • Inferior oil quality EAS28670 UNSTABLE HANDLING Fuel system 1. Handlebar 1. Throttle body(-ies) • Bent or improperly installed handlebar • Damaged or loose throttle body joint 2. Steering head components 2.
Page 565 TROUBLESHOOTING • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Headlight bulb life expired Tail/brake light does not come on • Faulty brake light switch • Too many electrical accessories • Incorrect connection • Faulty tail/brake light Turn signal does not come on •...
Page 566: Self-Diagnostic Function And Diagnostic Code Table
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS1TP1035 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-diagnostic function table Fault Reference Item code No. pages Crankshaft position sensor: no normal signals are received from the 7-48 crankshaft position sensor. Intake air pressure sensor: open or short circuit detected. 7-49 Intake air pressure sensor: hose system malfunction (clogged or de- 7-51...
Page 567 7-88 non-registered data has been received from the meter. Diagnostic code: sensor operation table The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the Yamaha diagnostic tool. Diagnostic Item Display Procedure code No.
Page 568 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. Air temperature Displays the air tempera- Compare the actually ture. measured air temperature with the display value. 07 (Except Vehicle speed pulses 0–999 Check that the number in- for ABS creases when the rear models)
Page 569 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. Neutral switch and clutch Operate the transmission, switch clutch lever, and side- stand. • Transmission is in neu- tral • Transmission is in gear or the clutch lever re- leased •...
Page 570 • Connect an ignition The “CHECK” indicator checker. and “ ” on the Yamaha diagnostic tool screen come on each time the ig- nition coil is actuated. Rear cylinder ignition coil Actuates the rear cylinder...
Page 571 (When the relay is on, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen go off. When the relay is off, the “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on.)
Page 572 F. Tail/brake light sub-wire har- Blue/White 28. Intake air pressure sensor ness Blue/Yellow 29. ISC (idle speed control) unit Pink/Blue 30. Yamaha diagnostic tool coupler Pink/White 31. ECU (engine control unit) Red/Black 32. Front cylinder ignition coil Red/Green 33. Spark plug Red/Blue 34.
Page 573 35. Intake air pressure sensor Red/Yellow F. Tail/brake light sub-wire har- 36. ISC (idle speed control) unit Sb/W Sky blue/White ness White/Black 37. Yamaha diagnostic tool coupler White/Green 38. ECU (engine control unit) White/Blue 39. Front cylinder ignition coil White/Red 40. Spark plug White/Yellow 41.
Page 577 XVS950CU/XVS950CUE XVS950CU/XVS950CUE (sauf pour XVS950CU/XVS950CUE XVS950CU/XVS950CUE XVS950CU/XVS950CUE (except for ABS models) 2014 modèles équipés d’ABS) 2014 (außer für Modelle mit ABS) 2014 (eccetto modelli ABS) 2014 (excepto modelos con ABS) 2014 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO B B B Y/L Lg (Gy)
Page 578 XVS950CU/XVS950CUE XVS950CU/XVS950CUE (sauf pour XVS950CU/XVS950CUE XVS950CU/XVS950CUE XVS950CU/XVS950CUE (except for ABS models) 2014 modèles équipés d’ABS) 2014 (außer für Modelle mit ABS) 2014 (eccetto modelli ABS) 2014 (excepto modelos con ABS) 2014 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO (Gy) (Gy) (Gy)
Page 579 XVS950CU (for ABS models) 2014 XVS950CU (pour modèles équipés XVS950CU (für Modelle mit ABS) XVS950CU (per modelli ABS) 2014 XVS950CU (modelos con ABS) WIRING DIAGRAM d’ABS) 2014 2014 SCHEMA ELETTRICO 2014 SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE B B B Y/L Lg (Gy) Gy/W R/W...
Page 580 XVS950CU (for ABS models) 2014 XVS950CU (pour modèles équipés XVS950CU (für Modelle mit ABS) XVS950CU (per modelli ABS) 2014 XVS950CU (modelos con ABS) WIRING DIAGRAM d’ABS) 2014 2014 SCHEMA ELETTRICO 2014 SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE (Gy) (Gy) (Gy) (Db) (Gy) (Gy)

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Xvs950cue 2014

Yamaha XVS950CU 2014 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Fuel System

Electrical System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha XVS950CU 2014